Grip

ABSTRACT

The disclosure herein includes a grip for a golf club with a flexible tube and a layered sheet. The tube includes a tubular body and raised portions extending from the tubular body. The outer surface of the raised portions cooperates with the layered sheet to form a gripping surface. The grip reduces impact shock and provides a feeling of tackiness while providing increased variation in the physical characteristics of the gripping surface. The disclosure further provides a golf club grip that includes a resilient strip spirally wrapped about an underlisting sleeve having a cap and a nipple. The underside of the cap is formed a downwardly facing circumferential slot that receives the upper edge of the strip. The nipple is formed with an upwardly facing groove that receives the lower portion of the strip.

RELATED U.S. APPLICATION DATA

This application is a continuation-in-part of U.S. patent applicationSer. No. 11/838,670, filed Aug. 14, 2007, pending.

This application is also a continuation-in-part of U.S. patentapplication Ser. No. 12/425,187, filed Apr. 16, 2009, pending, which isa continuation of U.S. patent application Ser. No. 11/412,196, filedApr. 25, 2006, pending, which is a continuation of U.S. patentapplication Ser. No. 10/167,216, filed Jun. 11, 2002, now U.S. Pat. No.7,137,904,

INCORPORATION BY REFERENCE

This application hereby incorporates by reference, in their entireties,U.S. Pat. Nos. 6,244,975, 6,627,027, 6,695,713, 6,843,732 and 6,857,971;U.S. Publication No. 2007/0004529; and U.S. patent application Ser. Nos.11/438,808, filed May 22, 2006, 11/417,643, filed May 3, 2006,11/417,696, filed May 3, 2006, 11/417,623, filed May 3, 2006,11/689,452, filed Mar. 21, 2007, 11/412,196, filed Apr. 25, 2006,10/167,216, filed Jun. 11, 2002, 12/425,187, filed Apr. 14, 2009, and11/838,670, filed Aug. 14, 2007.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This application relates to an improved grip, in particular an improvedgrip for use with golf clubs.

2. Description of the Related Art

Applicant has previously developed resilient grips which successfullyreduce impact shock to the muscle and arm joints of a user and alsoprovide a feeling of tackiness between a user's hands and the grip,improving upon prior art rubber grips. See, for example, U.S. Pat. No.5,797,813 granted to Applicant on Aug. 25, 1998, U.S. Pat. No. 6,843,732granted to Applicant on Jan. 18, 2005, and U.S. Pat. No. 6,857,971granted to Applicant on Feb. 22, 2005.

Some of these earlier grips utilize a polyurethane-felt strip which isspirally wrapped around an underlisting sleeve that is slipped onto andadhered to a golf club shaft. The sides of the strips are formed withoverlapping heat depressed recessed reinforcement edges. While suchgrips have proven satisfactory in reducing impact shock, the fabricationis labor intensive, particularly since the strip must be wrappedmanually about the underlisting sleeve within specific pressureparameters. Additionally, it is difficult to accurately align theadjoining side edges of the strip as such strip is being spiralingwrapped about the underlisting sleeve. Further, these wrapped grips canbecome twisted during the wrapping process.

Applicant's U.S. Pat. No. 6,857,971 disclosed a single panel grip whichin one embodiment provided the same tackiness and resistance to shockafforded by such grips.

Applicant's U.S. Pat. No. 6,843,732 disclosed multiple segmentsincorporated into a single panel, which is then applied to theunderlisting sleeve.

Applicant's U.S. Patent Publication No. 2007-0004529 disclosedincorporating multiple two layer sheet pieces onto a backing layer.

The present invention relates to an improved grip assembly for golfclubs and other sporting equipment employing handles subject to shockwhen such devices are impacted.

It is well known that the shock generated by impact between a golf cluband a golf ball can adversely affect muscle tissue and arm joints. Theenergy generated by such impact is usually of high frequency and shortduration with rapid decay and which is often known as “impact shock.”Tight grasping of a golf club grip to keep it from slipping in a user'shands contributes to such impact shock.

The Applicant has previously developed resilient grips whichsuccessfully reduce or even eliminate impact shock to the muscle and armjoint of the users of golf clubs. See for example U.S. Pat. No.5,797,813, granted to applicant Aug. 25, 1998. Such earlier gripsutilize a polyurethane layer bonded to a felt layer to define aresilient strip, which is spirally wrapped around an underlistingsleeve, with such underlisting sleeve being slipped over the handleportion of a golf club shaft.

A problem encountered with such grips is the tendency of thespirally-wrapped resilient strip to unravel from the golf club handlewhen a golf club is removed form and inserted into a golf bag. Thisproblem has existed since at least 1923 as evidenced by Howe U.S. Pat.No. 1,528,190 wherein the inventor stated:

-   -   “After using a club, the golfer often throws his club violently        into his bag; in doing so the handle end is of course within the        bag.    -   When the club is thrown into the bag in this way, the end of the        handle rubs along the inside of the bag and frequently results        in stripping the end of the leather beyond the cord wrapping.        Then the cord wrapping will become displaced or broken and it        will be necessary to repair the handle.”

My U.S. Pat. No. 6,386,989 discloses a golf club grip wherein the lowerend of the resilient strip is restrained from unraveling from theunderlisting sleeve by forming the upper portion of the nipple of thesleeve with a circumferential groove which receives the lowermost edgeof the strip, after which an outer peripheral lip defined by the grooveis folded upwardly over such lower edge. The lip snugly encompasses thestrip's lower edge and retains the lower edge against unraveling fromthe sleeve and hence the handle of the golf club during play, as well aswhen a golf club is inserted into and removed from a golf bag.

Despite these improvements, there remains the opportunity for additionalgrip advances.

SUMMARY OF THE INVENTION

Embodiments of the present disclosure include a tube preferably for usewith a golf club grip wherein the tube includes a body having a firstend, a second end including a cover, a support surface positionedbetween the first and second ends and a raised portion. The raisedportion extends outwards from the support surface and may be integrallyformed with the support surface. The cover may define a substantiallyclosed outer surface and extends outwards from the support surface. Theraised portion includes an exposed surface and a connecting surfaceextending between the support surface and the exposed surface. Theraised portion also extends along the body to form a finger zone on thebody. There is no slot in the underside of the cover, leaving thesupport surface adjacent the cover exposed. In some embodiments, theraised portion is integrally formed with the cover such that the exposedsupport surface adjacent the cover is adjacent the connecting surface ofthe raised portion.

Embodiments of the present disclosure include a grip preferably for usewith a golf club wherein the grip includes a tube having a body with afirst end, a second end including a cover, a support surface positionedbetween the first and second ends and a raised portion extendingoutwards from the support surface. The raised portion may be integrallyformed with the support surface and the cover may define a substantiallyclosed outer surface and may extend outwards from the support surface.The raised portion includes an exposed surface and a connecting surfaceextending between the support surface and the exposed surface. Theraised portion may also extend along the body to form a finger zone onthe body. The grip further includes a layered sheet including an innerlayer and an outer layer. The sheet is configured to overlay the supportsurface and not the exposed surface of the raised portion. The layeredsheet is wrapped about the tube such that the layered sheet contacts thesupport surface of the tube and the inner layer of the layered sheet maybe adhered to the support surface. The outer surface of the layeredsheet and the exposed surface of the raised portion cooperate to definea gripping surface positioned to be gripped by, for example, a golfer.The outer surface of the layered sheet and at least a portion of theouter surface of the cover extend outwardly substantially the samedistance. In some embodiments, the raised portion and the cover areintegrally formed such that they cooperate to form the end of the gripand the end region of the gripping surface.

The golf club grip of the present invention solves the problem of theupper end of the resilient strip of a golf club grip unraveling from thehandle of a golf club during play and particularly when the golf club isremoved from and inserted into a golf bag. Such problem is solved byforming the underside of the cap of the underlisting sleeve with acircumferential slot that snugly receives the upper edge of theresilient strip to prevent the strip from unraveling.

These and other features and advantages of the present invention willbecome apparent from the following detailed description of a preferredembodiment which, taken in conjunction with the accompanying drawings,illustrates by way of example the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Further objects, features and advantages of the inventions will becomeapparent from the following detailed description taken in conjunctionwith the accompanying figures showing illustrative embodiments of theinvention, in which:

FIG. 1 is a perspective view of a golf club incorporating a gripaccording to some embodiments;

FIG. 2 is a front view of a grip according to some embodiments;

FIG. 3 is a rear view of a tube according to some embodiments;

FIG. 4 is a side view of the tube shown in FIG. 3;

FIG. 5 is a front view of the tube shown in FIG. 3;

FIG. 6 is a horizontal sectional view taken along line 6-6 of FIG. 4;

FIG. 7 is a horizontal sectional view taken along line 7-7 of FIG. 5;

FIG. 8 is an enlarged view of the encircled area designated 8 in FIG. 6;

FIG. 9 is a front view of an embodiment of a layered sheet according tosome embodiments;

FIG. 10 is a vertical cross-sectional view taken along the linedesignated 10-10 in FIG. 9;

FIG. 11 is a horizontal cross-sectional view taken along the linedesignated 11-11 in FIG. 9;

FIG. 12 is a horizontal cross-sectional view showing a mold which may beutilized in forming a layered sheet of a grip according to someembodiments;

FIG. 13 is an enlarged view of the encircled area designated 13 in FIG.12;

FIG. 14 is an enlarged view of an exemplary pattern that may be formedby the mold shown in FIGS. 12 and 13;

FIG. 15 is an enlarged view of another exemplary pattern that may beformed by the mold shown in FIGS. 12 and 13;

FIG. 16 is a schematic view showing a portion of a method of making asheet according to some embodiments;

FIG. 17 is a top view of a portion of the schematic view shown in FIG.16;

FIG. 18 is a schematic view showing an apparatus for use in a portion ofa method of making a sheet according to some embodiments;

FIG. 19 is an enlarged view of the encircled area designated 19 in FIG.17;

FIG. 20 is an enlarged view of the encircled area designated 20 in FIG.19;

FIG. 21A is a SEM image at 100 times magnification of a cross-section ofa sheet made according to a method of some embodiments;

FIG. 21B is a SEM image at 500 times magnification of a portion of thecross-section shown in FIG. 21A;

FIG. 22A is a SEM image at 100 times magnification of a cross-section ofa sheet made according to a method of the prior art;

FIG. 22B is a SEM image at 500 times magnification of a portion of thecross-section shown in FIG. 21A;

FIG. 23 is a partial schematic cross-sectional view taken along the line23-23 in FIG. 19;

FIG. 24 is a partial schematic cross-sectional view of a painted sheet;

FIG. 25 is a front view of a layered sheet of a grip according to someembodiments;

FIG. 26 shows the bottom edge of a layered sheet being skived;

FIG. 27 shows a first side edge of a layered sheet being skived;

FIG. 28 shows a second side edge of the layered sheet shown in FIG. 27being skived;

FIG. 29 is a rear view showing adhesive being applied to a layered sheetof a grip according to some embodiments;

FIG. 30 is a front view showing adhesive being applied to the exteriorof a tube according to some embodiments;

FIG. 31 is a side elevational view showing a step in wrapping andadhering a layered sheet to a tube;

FIG. 32 is a side elevational view showing another step in wrapping alayered sheet around a tube;

FIG. 33 is a side elevational view showing a layered sheet after it hasbeen adhered to a tube according to some embodiments;

FIG. 34 is a horizontal sectional view taken along line 34-34 of FIG.31;

FIG. 35 is a horizontal sectional view taken along line 35-35 of FIG.32;

FIG. 36 is a horizontal sectional view taken along line 36-36 of FIG.33;

FIG. 37 is an enlarged view of the encircled area designated 37 in FIG.35;

FIG. 38 is an enlarged view of the encircled area designated 38 in FIG.36;

FIG. 39 illustrates the use of a nozzle in connection with the enlargedview shown in FIG. 38;

FIG. 40 is a partial cross-sectional view taken along the line 40-40 inFIG. 33;

FIG. 41 is a partial cross-sectional view taken along the line 41-41 inFIG. 2;

FIG. 42 illustrates the use of a nozzle in connection with the enlargedview shown in FIG. 41;

FIG. 43 is a side view of a tube according to some embodiments;

FIG. 44 is a horizontal sectional view taken along line 44-44 of FIG.43;

FIG. 45 is a rear view of a layered sheet of a grip according to someembodiments;

FIG. 46 is a horizontal sectional view of a layered sheet being wrappedaround a tube according to some embodiments;

FIG. 47 is a partial cross-sectional view of a layered sheet bonded to atube and a raised portion thereof according to some embodiments.

FIG. 48 is a broken perspective view showing the upper portion of aspirally-wrapped prior art golf club grip starting to unravel from thehandle of a golf club;

FIG. 49 is a top plan view of the golf club grip shown in FIG. 48;

FIG. 50 is a cut-away side view showing a golf club provided with aprior art golf club grip being inserted into a golf bag resulting in theunraveling of FIGS. 48 and 49;

FIG. 51 is a side view of an underlisting sleeve utilized in aspiral-wrap golf club grip embodying the present invention;

FIG. 52 is a vertical sectional view taken in enlarged scale along line52-52 of FIG. 51;

FIG. 53 is a cross-sectional view showing the upper portion of theunderlisting sleeve of FIG. 52;

FIG. 54 is a horizontal view taken along line 54-54 of FIG. 53;

FIG. 55 is a broken top view of a resilient strip of a grip embodyingthe present invention;

FIG. 56 is a bottom view showing the underside of the grip of FIG. 55;

FIG. 57 is a vertical sectional view taken in enlarged scale along line57-57 of FIG. 55;

FIG. 58 is a vertical sectional view taken in enlarged scale along line58-58 of FIG. 55;

FIG. 59 is a broken side elevational view showing the strip of FIGS.55-57 about to be spirally-wrapped about the underlisting sleeve ofFIGS. 51-54;

FIG. 60 is a broken side elevational view taken in enlarged scaleshowing the leading edge of the resilient strip being manually forcedinto an upwardly extending circumferential slot formed in the undersideof the cap of said underlisting sleeve;

FIG. 61 is broken side elevational view showing the resilient stripbeing spirally-wrapped about the underlisting sleeve;

FIG. 62 is a broken vertical sectional view taken in enlarged scalealong line 62-62 of FIG. 61;

FIGS. 63, 64, and 65 are broken side elevational views showing the lowerportion of the resilient sleeve being spirally wrapped around andsecured to the lower portion of the underlisting sleeve; and

FIG. 66 is a vertical cross-sectional view of grip embodying the presentinvention.

While the subject inventions will now be described in detail withreference to the figures, it is done so in connection with theillustrative embodiments. It is intended that changes and modificationscan be made to the described embodiments without departing from the truescope and spirit of the subject inventions.

DETAILED DESCRIPTION

There are numerous embodiments disclosed herein. As one of skill in theart will appreciate, when the specification refers to various featuresin the context of the “present invention”, it refers to features presentin some embodiments of the invention rather than in all iterations ofthe invention.

FIG. 1 shows one embodiment of a grip G attached to the shaft S of agolf club GC. FIG. 2 shows the grip G in greater detail.

Certain embodiments of grip G include a resilient mounting tube T and alayered member or sheet L wrapped about the tube T. The mounting tube Tincludes raised portions R which define one or more exposed surfaces E.Desirably tube T includes a tubular body 48 with one or more raisedportions R₁, R₂ . . . R_(n) having associated exposed surfaces E₁, E₂ .. . E_(n). In the illustrated embodiment, tube T includes two raisedportions R₁ and R₂ with exposed surfaces E₁ and E₂. The grip defines agripping surface GS. The gripping surface GS may include an outersurface of a layered sheet L and exposed surfaces E₁ and E₂ of raisedportions R₁ and R₂ of tube T. (See, e.g., FIG. 2).

More particularly, referring to FIGS. 3 through 8, there is shown oneembodiment of the resilient tube T. During the manufacture of a grip G,tube T may be mounted on a mandrel (not shown) as known to those ofskill in the art. Tube T includes a first end 2 and a second end 4. TubeT further includes a hollow inner cavity 3 configured to correspond tothe outer shape of the shaft GS of a golf club GC. An opening 6 and aring 8 are formed at the first end 2 while the second end 4 of tube T isformed with a cover 10, which in some embodiments substantially closesthe second end 4. Tube T has a support surface 12 extending generallybetween cover 10 and ring 8. In some embodiments, tube T is formed of aresilient material such as a natural or synthetic rubber or plastic. Forexample, the rubber might include a mixture of synthetic rubber, forexample EPDM (Ethylene Propylene Diene Monomer) and natural rubber.Other examples include TPE (Thermoplastic Elastomer), TPR (ThermoplasticRubber), TPU (Thermoplastic Polyurethane), and TPV (ThermoplasticVulcanizate). In some embodiments, the ratio of synthetic rubber tonatural rubber is approximately 2 to 3.

As known to those of skill in the art, tube T may be formed in a mold(not shown). In some embodiments, raised portions R₁ and R₂ areintegrally formed on tubular body 48. In such instances, tubular body 48and raised portions R₁ and R₂ may comprise the same material. If this isthe case, forming raised portions R₁ and R₂ merely requires creating theinverse of raised portions R₁ and R₂ in the mold. In such cases, thematerial is selected to enhance the properties desired for raisedportions R₁ and R₂ while balancing the desired properties for tubularbody 48. In some instances, it may be desired to control the durometer,tackiness, resistance to torque, durability, color, or other property ofraised portions R₁ and R₂ to enhance certain properties of completedgrip G.

As shown in FIG. 7, a connecting surface 46 a forms an angle α₁ with aline tangent to the intersection of connecting surface 46 a of raisedportion R₁ and support surface 12 of tube T. In general, connectingsurface 46 desirably extends between support surface 12 and exposedsurface E of raised portion R and forms an angle α. In some embodiments,angle α is in the range of approximately 5 and 175 degrees. In someembodiments, angle α is in the range of approximately 5 and 90 degrees.In some embodiments, angle α is in the range of approximately 90 and 175degrees. In some embodiments, for example the embodiment shown in FIG.7, angle α is approximately 90 degrees.

In general, raised portion R extends a width w around the circumferenceof body 48 of tube T. Width w may be constant along tube T, for exampleif raised portion R forms a rectangular shape. Alternatively, width wmay vary along tube T. In some embodiments, width w may extend to amaximum distance around the circumference of tube T (expressed as apercentage of the circumference of the body 48 of tube T) in the rangeof approximately 25% to 75%. In some embodiments, width w may extend toa maximum in the range of approximately 5% to 25%. In some embodiments,width w may extend to a maximum in the range of approximately 75% to100%. In some embodiments, width w may vary along the longitudinallength of R. For example, in the illustrated embodiment, raised portionR₁ defines an elliptical shape with a width w₁ starting near zero andwidening to approximately 50% and narrowing back to near zero along tubeT from first end 2 to second end 4. Width w need not vary consistentlyalong tube T. Referring to FIGS. 3 through 5, in the illustratedembodiment raised portion R₁ is configured to form a thumb zone TZ inthe gripping surface GS. Thumb zone TZ is shown on the front of tube Tto accommodate a user's thumbs when that user employs a traditional golfgrip with some or all of the fingers overlapping and/or interlocking onthe back of the grip and the thumbs resting on or near the front of thegrip. As will be understood by one of skill in the art, thumb zone TZmay be placed in other areas of gripping surface GS to accommodatedifferent grips.

In some embodiments raised portion R₁ extends at least the length of anadult's finger pad in a circumferential direction. In some embodiments,raised portion R₁ extends at least the length of an adult's finger padalong the longitudinal direction. In some embodiments, raised portion R₁extends at least the length of two adult finger pads along thelongitudinal direction. For purposes of this application, the length ofan adult's finger pad is defined as being one inch.

In some embodiments, the upper portion of raised portion R₂ adjacentcover 10 extends a width w₂ of 100% of the circumference of tube T. Insome such embodiments, raised portion R₂ is formed integrally with cover10 such that the transition between cover 10 and raised portion R₂ issubstantially smooth. As shown in, for example, FIGS. 3 through 5,raised portion R₂ may extend further down the length of tube T fromsecond end 4 toward first end 2 on the back of tube T than it does onthe front of tube T. As described in greater detail below, such anextended region can provide a finger zone FZ in the gripping surface GSwith characteristics different than those provided by the layered sheetL in other regions of the gripping surface GS. In some embodiments,finger zone FZ of raised portion R₂ extends at least the width of 4adult finger pads along tube T from second end 4 toward first end 2. Forpurposes of this application, the width of an adult finger pad isdefined as being one half inch.

In some embodiments, the upper portion of raised portion R₂ in the frontof tube T is configured to form a palm zone PZ in gripping surface GS.In some embodiments, palm zone PZ of raised portion R₂ extends at leastthe width of one adult finger pad along tube T from second end 4 towardfirst end 2. In some embodiments, palm zone PZ extends at least thewidth of 2 or more adult finger pads along tube T from second end 4toward first end 2.

Friction may be enhanced on raised portion R by forming ridges orvalleys in various patterns 47 on surface E of raised portion R. Asshown in, for example, FIG. 5, different patterns 47 a and 47 b may beused. The patterns may be different on different raised portions or thesame or similar patterns may be used. In some embodiments, the patternsare formed as raised portion R is molded. In other embodiments, thepatterns are applied by altering surface E of portion R after themolding process, such as by grinding surface E.

In some embodiments, one or more of the raised portions R may be formedseparately from tubular body 48 and attached to tubular body 48 throughbonding, adhesive or other mechanisms known to those of skill in the artto form tube T. Separately forming a portion R may facilitate using adifferent material to form the particular raised portion R than is usedto form tubular body 48. In embodiments where multiple raised portionsare desired, separately forming one or more of the portions allows for awide variety of different materials to be incorporated into the grip. Itis also possible for some portions to be formed integrally with tubularbody 48 while others are attached after tube T is molded. Raised portionR is generally configured with a thickness t_(R) as shown in FIG. 7.

Referring to FIG. 8, ring 8 of tube T may be formed with an upwardlyextending slot 30 defined by a portion 32 of support surface 12 of tubeT and lip 34 extending upwardly from ring 8 and preferably wrappingsubstantially circumferentially around tube T. Lip 34 defines an innersurface 36 facing tube T, an upper surface 38 facing upward from ring 8,and an outer surface 40 facing away from support surface 12 of tube T.Upwardly extending lip 34 extends over portion 32 of support surface 12of tube T. The lower-most portion of slot 30 is defined by an inner,lower, upwardly facing surface 42. Though lip 34 may flex outward fromtube T, in many embodiments it resists remaining in a fully flexedposition in which it lays flat, thereby fully exposing tube T supportsurface 12. In alternative embodiments, outer surface 40 tapers towardinner surface 36, or inner surface 36 tapers toward outer surface 40such that upper surface 38 is comparatively narrow and in someembodiments is an annular point extending substantiallycircumferentially around tube T. Slot 30 receives, for example, thebottom region of a layered sheet L. To assist in installation of alayered sheet L, in some embodiments tube T will be formed withcentering notches (not shown) disposed on an outer surface of cover 10,ring 8 and/or both.

Referring now to FIGS. 9 through 15 a layered sheet L for use with tubeT is described. Various aspects and attributes of layered sheet L may becombined from the disclosure below. Generally, layered sheet L has athickness t_(L) (FIG. 11) and includes an outer surface 174 and an innerlayer 50 having its outer face bonded to the inner face of an outerlayer 52. Outer layer 52, in some embodiments, comprises a polymer. Insome embodiments, that polymer comprises polyurethane. Additionalmaterials such as waterproofing coatings may be incorporated on outersurface 174. Similarly, other materials such as fabric meshes may beincorporated into outer layer 52. Inner layer 50 may be fabricated of afibrous material including, for example, wool, polyester, nylon, ormixtures thereof. In certain embodiments, a nylon polyester fibrousmaterial such as felt is used. During the manufacturing process, some ofouter layer 52 may permeate inner layer 50. For example, whenpolyurethane is used in the outer layer and a fibrous material is usedin the inner layer, some polyurethane may permeate the fibrous layer. Inanother embodiment, inner layer 50 may comprise a polymer, such as, forexample, ethylene vinyl acetate (EVA).

Outer layer 52 may provide a cushioned grasp for a golfer's hands on agolf club and may enhance the golfer's grip by providing increasedtackiness between the golfer's hands and the grip. Inner layer 50 mayprovide strength to outer layer 52 and serve as a means for attachingthe bonded-together layered sheet L to the tube T.

The outer surface of inner layer 50 in some embodiments is bonded to theinner surface of outer layer 52. For purposes of this disclosure, thedefinition of bonding is intended to have a broad meaning, includingcommonly understood definitions of bonding, adhering, fixing, attaching,sewing, coupling, and gluing. As will be appreciated by those of skillin the art, the foregoing terms have their ordinary meaning. In someembodiments, the material used in the outer layer may penetrate somedistance into the inner layer. When polyurethane is used in outer layer52, such polyurethane is preferably coagulated to define pores, asshown, for example, in FIG. 21A. The polyurethane may be coagulated andbonded directly to inner layer 50 or may be first coagulated on anintermediary layer (not shown) and later attached to inner layer 50.

Layered sheet L may include centering notches (not shown) positioned atthe top region A and/or the bottom region B of the layered sheetindicating a middle point between a first side region C₁ and a secondside region C₂. Centering notches may assist in the application oflayered sheet L to tube T to form grip G. Layered sheet L is configuredto correspond with tube T and, in particular, has been adapted tocorrespond with raised portions R₁ and R₂. Layered sheet L includescut-out 184. Cut-out 184 is substantially elliptical in shape defined byedge 190 and has its major axis substantially parallel to thelongitudinal axis of tube T. As such, cut-out 184 corresponds to theoverall shape of raised portion R₁. Top region A is defined by edge 192shaped to correspond to the lower edge of raised portion R₂.

Referring now to FIGS. 12 through 15, there is shown a mold M which isutilized to form a friction enhancing pattern 54 as known to those ofskill in the art. Friction enhancing pattern 54 may take any of a numberof forms or combinations thereof. For example, two such patterns 54 aand 54 b are shown in FIGS. 14 and 15, respectively. In alternativeembodiments, mold M forms logos, designs, insignias and other marks (notshown) in outer layer 52. Mold M in one embodiment includes a heatedplaten 56 formed with a cavity 58. Platen 56 is provided with dependingprotrusions 60 that engage outer surface 174 of layered sheet L so as toform depressed friction enhancing pattern 54, as seen in FIG. 13.Friction enhancing pattern 54 may also be applied to the other layeredsheets described below.

In alternative embodiments, other patterns may be formed on or in outerlayer 52. These patterns may also incorporate stamped visual indicia,including designs or logos, on layered sheet L. In some embodiments,stamped visual indicia is ink stamped onto outer layer 52 using asuitable ink known to those of skill in the art. The ink in someimplementations is waterproof, heat resistant and formulate d to resistdegradation when coming into contact with a lubrication fluid or solventwhich may be used to apply completed grip G over the end of golf clubshaft CS (FIG. 1). It is to be understood that many other patterns andstamps may be used with other embodiments of the grip disclosed herein.

Though not shown in the figures, a multi-segment single panel asdisclosed in U.S. Pat. No. 6,843,732, incorporated herein in itsentirety, may also be applied to tube T as described herein. In someembodiments, raised portion R on tube T facilitates attachment of themulti-segment single panel disclosed in the '732 patent to tube Twithout first skiving some or all of the outer regions of the panel.Similarly, a layered sheet including cutouts and corresponding layeredinserts as disclosed in U.S. patent application Ser. No. 11/417,643,incorporated herein in its entirety, may also be applied to tube T asdescribed herein.

Referring to FIGS. 16 through 25, there is shown a method of forming asheet 80 having an inner layer and an outer layer that can be shapedinto another layered sheet L2 (FIG. 25). Referring to the upperright-hand portion of FIG. 16, there is shown a supply roll 82 ofsubstrate 84. Substrate 84 has a top surface 86 and a bottom surface 88.In some embodiments, substrate 84 includes a fibrous material, forexample felt or other fabrics, which may include wool, polyester, nylon,or mixtures thereof. In one embodiment, substrate 84 comprises a fabricincluding nylon and polyester. From the supply roll 82, substrate 84 ismoved horizontally to the left below a first polyurethane dispensingmachine 90. The first dispensing machine 90 preferably continuallydeposits a first region of liquid polyurethane 92, for example polyesteror polyether dissolved in dimethyl formahide (DMF), onto top surface 86of substrate 84 to form first web 94. The first dispensing machine 90preferably uses a nozzle, sprayer or the like to deposit the firstpolyurethane region 92 and preferably uses a blade to control thethickness of the first polyurethane region 92. First polyurethane region92 has a top surface 96 and a bottom surface 98.

As first web 94 continues to the left from first dispensing machine 90,a second polyurethane dispensing machine 100 deposits a second liquidpolyurethane region 102 onto at least a portion of top surface 96 offirst polyurethane region 92 to form a second web 104. Secondpolyurethane region 102 has a top surface 106. Second web 104 is thenmoved into a water bath 108 contained in a first tank 110. As second web104 is immersed in water bath 108, polyurethanes 92 and 102 willcoagulate so as to form a coagulated region 112 on substrate 84.Coagulated region 112 and substrate 84 cooperate to form sheet 80wherein the coagulated region forms the outer layer and the substrateforms the inner layer. Coagulated region 112 has a top surface 144 and abottom surface 114.

As is known, the coagulation time of the polyurethane will be determinedby the desired thickness of coagulated region 112, with a thin regionrequiring less time to coagulate than a thick region. In someembodiments, the coagulation process bonds bottom surface 114 ofcoagulated region 112 to top surface 86 of substrate 84 so as to fixcoagulated region 112 to substrate 84. This bond interface 116 is shownin FIG. 21A. A pair of rollers 118 and 120 are positioned within tank110 to carry sheet 80 horizontally and then upwardly out of water bath108 over roller 122. Sheet 80 is then moved horizontally to the rightbetween a pair of squeezing rollers 124. These squeezing rollers 124compress sheet 80 so as to force a major portion of the DMF disposedwithin pores 126 downwardly through substrate 84. Referring to FIG. 21A,the bottom end of a sufficient number of the pores are in contact withtop surface 86 of substrate 84 to permit fluid flow from the poresthrough substrate 84. Referring again to FIG. 16, sheet 80 is then moveddownwardly through one or more cleaning water bath tanks 128 (only oneof which is shown), wherein the temperature of the water is sufficientlyhigh to displace more DMF from the pores, with such DMF being replacedby water 130 contained in tank 128. From tank 128, sheet 80 passesthrough another pair of squeezing rollers 132 to squeeze more of the DMFout of the pores to be replaced with water 130. In practice, it may benecessary to utilize four or five cleaning baths to remove a desiredamount of DMF from the pores. From the last water bath, sheet 80 ispassed through a heating chamber (not shown) which drives out any waterremaining within pores 126 so that such water is replaced by air.

In another embodiment (not shown), substrate 84 includes a flexibletemporary support for the polyurethane during the wet coagulationprocess described above. Such a temporary support would be configured tobe removed from bottom surface 114 of coagulated polyurethane region 112after sheet 80 is formed. In such an embodiment, bond interface 116 isdesirably relatively weak to facilitate separation of coagulated region112 from substrate 84. One temporary support includes a smooth, flexiblenylon cloth and is available from the Ho Ya Electric Bond Factory, XinXing Ind. Area. Xin Feng W. Rd., Shi Jie Town Dong Guan City, Guan DongProvince, China. Other materials include fluid-permeable textiles suchas cotton or a synthetic cloth such as polyester. Generally, thetemporary support would have the fluid-passing characteristics andsmooth top surface of nylon cloth allowing the DMF and water to besqueezed out of the polyurethane pores and allowing the coagulatedpolyurethane to be readily stripped off such temporary support. Removingsubstrate 84 from coagulated polyurethane region 112 provides for use ofcoagulated polyurethane region 112 alone or provides the opportunity touse an alternative substrate. For example, it is possible to replace thefabric substrate with a polymer substrate such as ethylene-vinyl acetate(EVA). The EVA substrate may include an adhesive coating to bond the EVAsubstrate to coagulated polyurethane region 112. EVA having an adhesivecoating covered by a protective paper is sold by the aforementioned HoYa Electric Bond Factory.

Referring now to FIG. 18, a schematic illustration of second dispensingmachine 100 is shown. In FIG. 18, dispensing machine 100 includes afirst housing 134 having a first dispensing nozzle 136. Housing 134 isconnected to perpendicular rail 138 extending along the Y axis asillustrated. Rail 138, in turn, is connected to parallel rails 140extending along the X axis as illustrated. Dispensing machine 100 isconfigured to allow first web 94 of substrate 84 and first polyurethaneregion 92 to pass beneath nozzle 136, preferably at a constant pace,along the X axis (see FIGS. 16 and 17). First polyurethane region 92 mayprovide a base region for the second polyurethane region 102. In someregions, second polyurethane region 102 may extend completely throughfirst polyurethane region 92 to be in contact with substrate 84.Dispensing machine 100 is preferably further configured to move nozzle136 in one or both of the X and Y directions. In addition, nozzle 136may be configured to start and stop depositing second polyurethane 102as desired. The movement of nozzle 136 in the X and Y directions and thestart/stop feature of the nozzle 136 provides for the ability to createa unique appearance which may include random or semi-random patterns 142in second web 104 and, in turn, in sheet 80 (see FIG. 17). In otherembodiments, web 94 is moved beneath a stationary nozzle 136 to create apattern. For example, nozzle 136 could be fixed along the X axis and thepace with which web 94 is moved under nozzle 136 can be varied.Similarly, nozzle 136 could be fixed along the Y axis and web 94 can beshifted along the Y axis instead. Alternatively, nozzle 136 can be movedin both directions.

In other embodiments (not shown), dispensing machine 100 may includetwo, three or more nozzles for dispensing third, forth, etc.polyurethane regions. Such additional nozzles may be included in thesame housing, separate housings or a combination thereof. It is alsopossible to include additional dispensing machines on separate rails tointroduce still further variation in the application of the polyurethaneregions.

Referring now to FIG. 19, there is shown an enlarged view of pattern 142formed in coagulated polyurethane region 112 of sheet 80. Generally, topsurface 144 of coagulated region 112 includes pattern 142 because firstpolyurethane 92 and second polyurethane 102 each include at least onecontrasting characteristic. In the illustrated embodiment, thecontrasting characteristic is color. However, other contrastingcharacteristics, or combinations thereof, could be incorporated tocreate the pattern such as contrasting durometers or levels oftackiness. In the figures, first polyurethane 92 defines a first color146 and second polyurethane 102 defines a second color 148. As shown ingreater detail in FIG. 20, pattern 142 on top surface 144 of coagulatedregion 112 includes a first region 150 and a second region 152 definedby first color 146 of first polyurethane 92 and second color 148 ofsecond polyurethane 102, respectively.

As described above, the two polyurethanes 92 and 102 are coagulated ontosubstrate 84 in first water bath 108. The application of secondpolyurethane 102 onto a portion of top surface 96 of first polyurethane92 prior to coagulation allows for the polyurethanes to mix andintegrate below top surface 96 of the first polyurethane region suchthat coagulation of the polyurethanes forms the single coagulated region112 (see FIGS. 21A and 21B). Despite the mixing of the two polyurethanesprior to coagulation, and the integration of the two polyurethanesduring coagulation, each of the polyurethanes substantially maintainsits original characteristics. The contrast in one or morecharacteristics of the polyurethanes creates pattern 142. Though thecharacteristics remain substantially distinct, there may be someblending along the interface of the two polyurethanes.

In the illustrated embodiment, top surface 96 of first polyurethaneregion 92 cooperates with top surface 106 of second polyurethane region102 to form substantially smooth top surface 144 of coagulated region112. Contrasting colors 146 and 148 on surface 144 cooperate to createpattern 142. If the first polyurethane is red and the secondpolyurethane is white, the process discussed above would result in acoagulated polyurethane region with distinct red and white regions,rather than a single blended pink region. Though the contrastingcharacteristics of first 92 and second 102 polyurethanes remainsubstantially distinct, the polyurethane structure below top surface 144is preferably seamless between the different polyurethanes with apreferably continuous pore structure throughout (see FIGS. 21A and 21B).

FIG. 21A is a 100 times magnification of a cross-section of a samplecoagulated sheet 80 taken along the line 21-21 in FIG. 20. FIG. 21Ashows substrate 84, in the sample a polyester nylon fabric, with its topsurface 86 bonded to bottom surface 114 of coagulated polyurethaneregion 112 along bond interface 116. Top surface 144 is generallysmooth. The structure is desirably substantially seamless on both thetop surface 144 between first region 150 and second region 152 andsubstantially seamless inside coagulated region 112 where firstpolyurethane 92 interfaces with second polyurethane 102. It is apparentthat the structure is not just seamless and not just coagulated, but thetwo polymers polymerize with each other to form coagulated region 112.Accordingly, in the illustrated embodiment coagulated region 112 is apolymerized region. Coagulated region 112 preferably includes aplurality of generally vertically extending pores 126, top surface 144,and bottom surface 114. Pores 126 generally form substantiallythroughout coagulated region 112 including in the regions where firstpolyurethane 92 interfaces with second polyurethane 102 between top 144and bottom 114 surfaces. Though polyurethane is preferred to form thecoagulated region, other liquid polymers having contrastingcharacteristics may be used. Generally, the polymers will be combinedwhile in their liquid states and allowed to polymerize together. As thepolymers polymerize together, the structure of polymerized region 112will preferably be seamless while maintaining the contrastingcharacteristics at least on outer surface 144 of polymerized region 112.

FIG. 21B is a 500 times magnification of a portion of the cross-sectionshown in FIG. 21A. As is apparent from the figures, first 92 and second102 polyurethanes are coagulated together to form coagulated region 112with a substantially seamless structure between first color region 150and second color region 152 and between the polyurethanes insidecoagulated region 112.

FIGS. 21A and 21B may be contrasted with a prior art method of usingpaint to create a sheet with multiple colors, as shown in FIGS. 22A and22B. In the prior art, a single polyurethane region 154 is coagulatedonto a substrate 156 to form a sheet 158 including a coagulated region160 having a top surface 168 and a bottom surface 170. To achieveregions of different color, a paint 162 having a top surface 164 and abottom surface 166 would be applied to top surface 168 of coagulatedpolyurethane region 160 where desired. The polyurethane was coagulatedprior to application of the paint and the paint would form a thinseparate region over the surface of the coagulated polyurethane.

The prior art method of coating a coagulated region of polyurethane 160with paint 162 alters the characteristics of sheet 158. As shown in FIG.22A and in greater detail in FIG. 22B, paint 162 did not integrate withpolyurethane region 154. Rather, bottom surface 166 of paint 162 bondsto top surface 168 of polyurethane region 154. In embodiments known tothe Applicant, the paint coating the surface had different tactilecharacteristics from the polyurethane it coated, including differentlevels of tackiness or durometer. For example, painted grips aregenerally less tacky in the region covered by paint than in theunpainted regions of polyurethane. In addition, during use, the paint onthe polyurethane may wear off giving the grip a weathered or wornappearance. Though valuable and unique, Applicant's other solutions forintroducing contrasting characteristics (including the use of multiplesheets, strips and/or inserts) result in seams between the variouscomponents.

Embodiments created according to the above description allow for themanufacture of grips having regions of contrasting characteristicswherein the structure of the region is seamless. For example, a redpolyurethane having a desired level of tackiness and durometer may beused in conjunction with a blue polyurethane having the same desiredlevel of tackiness and durometer. The sheet formed from the twomaterials would include a uniquely colored pattern and a seamlessstructure having a substantially uniform level of tackiness anddurometer.

Referring now to FIG. 23, there is shown a partial schematiccross-sectional view of sheet 112 taken along the line 23-23 in FIG. 19.Contrasting regions 150 and 152 are visible on top surface 144. Due tothe movement of nozzle 136 relative to web 94 during the application ofsecond polyurethane 102 onto top surface 96 of first polyurethane 92, asdiscussed above, differing amounts of second polyurethane 102 areapplied in different areas or regions. As the polyurethanes mix, secondpolyurethane 102 settles into first polyurethane 92.

After water bath 108, coagulated region 112 defines a total thicknesst_(PolyT) between its top surface 144 and its bottom surface 114. Invarious regions, second polyurethane 102 extends from top surface 144into coagulated region 112 with a thickness t_(poly2). The ratio oft_(Poly2) to t_(polyT) may vary, depending on a number of factorsincluding the speed with which web 94 passes below nozzle 136, the flowrate of second polyurethane 102 from nozzle 136, and the rate ofmovement of nozzle 136 in the X and Y directions. In some embodiments,the maximum and, preferably, the average ratio of t_(Poly2) to t_(PolyT)in some regions is at least 1 to 15, 1 to 10, 1 to 5, 1 to 4, 1 to 3,and/or 1 to 2. In some regions, the ratio is 1 to 1 where secondpolyurethane 102 extends from top surface 144 to bottom surface 114. Insome embodiments, the ratio varies in different regions of sheet 80.

As discussed above, coagulated region 112 is generally porous. Thisporous region has a total thickness t_(porousT) between top surface 144and bottom surface 114 of coagulated region 112. In various regions,second polyurethane 102 extends from top surface 144 into porouscoagulated region 112 with a maximum thickness t_(porous2). The ratio oft_(porous2) to t_(porousT) may vary. In some embodiments, the maximumand, preferably, the average ratio of t_(porous2) to t_(porousT) in someregions is at least 1 to 50, 1 to 40, 1 to 30, 1 to 20, 1 to 15, 1 to10, 1 to 5, 1 to 4, 1 to 3, and/or 1 to 2. In some regions, the ratio is1 to 1 where second polyurethane 102 extends through porous coagulatedregion 112 from top surface 144 to bottom surface 114. In someembodiments, the ratio varies in different regions of sheet 80.

Pattern 142 shown in the figures is an example of the patternsachievable with Applicant's method of making the polyurethane sheet.Other patterns are also possible. For example, in some embodiments,nozzle 136 is held steady as second polyurethane 102 is applied to web94 to create a solid band of second polyurethane 102 across uppersurface 96 of first polyurethane 92. Depending on how sheet 80 is formedinto layered sheet L2, the band may extend horizontally, vertically, orat an angle on layered sheet L2.

In some embodiments, top surface 96 of first polyurethane region 92forms substantially all of top surface 144 of coagulated region 112. Insuch embodiments, relatively smaller quantities of second polyurethane102 may be applied prior to the coagulation process. In otherembodiments, top surface 106 of second polyurethane 102 formssubstantially all of top surface 144 of coagulated region 112. In suchembodiments, relatively large quantities of second polyurethane 102 maybe applied prior to the coagulation process. Embodiments of the presentinventions may include different regions of similar patterns. In some,the pattern may be repeated and positioned such that layered sheet L2formed from the sheet includes at least three regions having contrastingcharacteristics, such as colors. In some embodiments, layered sheet L2may be formed with at least 5 regions of contrasting characteristics. Insome, there may be at least 7 regions of contrasting characteristics. Insome, there may be 10 or more regions of contrasting characteristics.These regions of contrasting characteristics may be arranged throughouttop surface 144 of coagulated region 112 of layered sheet L2, whetheracross the width of layered sheet L2, along the length of layered sheetL2, or in a combination of the two.

Referring now to FIG. 24, there is shown a partial schematiccross-sectional view of sheet 158 shown in FIGS. 22A and 22B. Coagulatedregion 160 is porous and includes generally smooth top surface 168 andbottom surface 170. Top surface 168 may include one or moreirregularities 172 which may extend downward into coagulated region 160.Paint 162 is applied over top surface 168 of coagulated region 160. Dueto irregularities 172 in top surface 168 of coagulated region 160, paint162 may extend into coagulated region 160 with a thickness t_(Porous2).Though unclear, the ratio of t_(porous2) to t_(PorousT) shown in FIG.22B appears to be no more than 1 to 100. Thus, if the paint was a secondpolymer applied to the surface of a coagulated region, the ratio oft_(porous2) to t_(PorousT) of a paint covered sheet is far from the 1 to50 ratio discussed above.

As shown in FIG. 25, sheet 80 may be formed into layered sheet L2. Insome embodiments, layered sheet L2 is die cut from sheet 80. As will beunderstood by those of skill in the art, sheet 80 may be formed into anyof a number of shapes, including strips, panels, inserts, or panels withcut-outs as may be appropriate for the particular application.

Like layered sheet L described above, layered sheet L2 includes a topsurface 174, a top region A, a bottom region B, a first side region C₁,and a second side region C₂. A line drawn from top region A to bottomregion B on at least a portion of top surface 174 preferably crossesmultiple regions of polyurethane having a different characteristic. Insome embodiments, layered sheet L2 may include at least 2, at least 3,at least 5, at least 7, or at least 10 regions having a differentcharacteristic along the line drawn from top region A to bottom region Bon at least a portion of top surface 174. In some embodiments, layeredsheet L2 may include in the range of between 2 and 500 regions of atleast one different characteristic along the line. It should beunderstood that the different characteristics of the regions may bealternating two or more colors along the line. Alternatively, thedifferent characteristics of the regions may be alternating levels ofother characteristics such as tackiness or durometer along the line.

Similarly, a line drawn from first side region C₁ to second side regionC₂ on at least a portion of top surface 174 also will preferably crossmultiple regions having different characteristics. In some embodiments,layered sheet L2 may include at least 2, at least 3, at least 5, atleast 7, or at least 10 regions having a different characteristic alongthe line drawn from first side region C₁ to second side region C₂ on atleast a portion of top surface 174. In some embodiments, layered sheetL2 may include in the range of between 2 and 500 regions of at least onedifferent characteristic along the line.

Likewise, a line drawn into layered sheet L2 from top surface 174 tobottom surface 114 of coagulated region 112 may cross multiple regions.In some embodiments, layered sheet L2 may include at least 2, at least3, at least 5, at least 7, or at least 10 regions having differentcharacteristics along the line drawn from its top surface 174 to bottomsurface 114 of coagulated region 112. In some embodiments, layered sheetL2 may include in the range of between 2 and 50 regions of at least onedifferent characteristic along the line.

As will be understood by those of skill in the art, features of layeredsheet L2 may be combined with features of layered sheet L discussedabove as desired. For example, as discussed above with respect to theother layered sheets, layered sheet L2 may be further enhanced with afriction enhancing pattern.

FIG. 26 illustrates another step in the manufacture of embodiments ofgrip G. Layered sheet L is illustrated, but one of skill in the art willunderstand that similar steps may be taken with layered sheet L2. Insome embodiments, bottom region B of layered sheet L is skived.Generally, top region A need not be skived as raised portion R₂ of tubeT includes substantially axially extending surfaces 46 b which engagetop region A when layered sheet L is attached to tube T. It will benoted that, in some embodiments not shown, top region A of layered sheetL can be skived at various angles to accommodate different angles α₂ ofsurface 46 b as desired.

FIGS. 27 and 28 illustrate another skiving step in the manufacture ofembodiments of grip G. Side regions C₁ and C₂ are shown being skivedsuch that they are substantially parallel to each other. Skiving sideregions C₁ and C₂ in such a manner may facilitate the attachment oflayered sheet L to tube T in certain embodiments as described in greaterdetail below. Other possible skiving configurations are possible inaddition to leaving the side regions unskived.

Referring generally to the layered sheets disclosed herein, top surface174 of layered sheet L is in direct contact with the hand of the userusing a grip G. However, as one of skill in the art would appreciate, anadditional coating region over layered sheet L may be included. Itshould be understood that the top surface of a grip embodying thedisclosure presented above may also be coated, in whole or in part, bymeans of a brush, nozzle, spray or the like with a thin region ofpolyurethane and/or other material (not shown) to, for example, protectsuch surface, add tackiness thereto, and/or increase the durabilitythereof. The additional coating region is preferably transparent, orsemi-transparent, such that some or all of any visual pattern on theouter surface of layered sheet L remains visible. The additional coatingregion may be somewhat opaque, as long as a portion of the layered sheetL is observable through the additional coating region. The additionalcoating region may be incorporated into a previously formed grip G ormay be applied to the layered sheet L prior to attachment to tube T. Ifused, the additional coating region would be in direct contact with theuser's hand rather than the top surface of the layered sheet. However,even when an additional coating region is included, the top surface ofthe layered sheet L is considered to be the top surface of the grip G.If an additional coating region is included over the top surface of thegrip, this region may also be further enhanced with a friction enhancingpattern as discussed herein.

Referring now to FIGS. 29 through 42, layered sheet L is shown beingapplied to tube T to form grip G. In FIG. 29 the inner surface of layer50 is shown receiving an adhesive 180 by means of a nozzle, brush or thelike. In FIG. 30 support surface 12 of tube T is shown receiving anadhesive 180 by means of a nozzle, brush or the like. In someembodiments, adhesive 180 is applied to either layered sheet L or tubeT.

FIGS. 31 through 42 shows the layered sheet L being wrapped around andadhered to tube T. Combined layered sheet L and tube T form grip G (FIG.33). As the manufacturing process progresses, tube T will generally betemporarily supported on a collapsible mandrel (not shown) in aconventional manner. During the wrapping operation, bottom region B oflayered sheet L will desirably be manually inserted within slot 30 ofring 8. Raised portion R₁ desirably fits within cut-out 184 and isdesirably substantially engaged by edge 190 of cut-out 184. Top regionA, defined in part by edge 192, is configured to correspond to raisedportion R₂. When layered sheet L is wrapped about support surface 12,raised portion R₂ desirably engages edge 192 in the upper portion of thegrip G.

In some embodiments, side regions C₁ and C₂ cooperate to form a seam 200extending generally along the longitudinal axis of tube T. As shown inFIGS. 31 through 39, in some embodiments the side regions C₁ and C₂ areskived in a substantially parallel fashion such that they overlap alongthe seam 200. In such embodiments, inner layer 50 of side region C₁preferably corresponds to inner layer 50 of side region C₂ and outerlayer 52 of side region C₁ preferably corresponds to outer layer 52 ofside region C₂ to form a strong and relatively smooth seam. Otherpossible seams 200 may be formed. For example, un-skived side regions C₁and C₂ may be adhered or bonded together. Alternatively, side regions C₁and C₂ may be stitched together to form the seam 200. In someembodiments, side regions C₁ and C₂ are skived from the center oflayered sheet L toward the outer regions of layered sheet L in ananti-parallel fashion and subsequently joined to form seam 200. Suchskiving may start at inner layer 50 and extend through outer layer 52,leaving a thin layer of outer layer 52 at the outer portion of sideregions C₁ and C₂. In some embodiments, a groove (not shown) may beformed along seam 200 to further enhance seam 200. In some embodiments,seam 200 may include, in addition to adhesive 180, a deposit ofpolyurethane 202 to assist in bonding or adhering layered sheet L, andin particular outer layers 52 of layered sheet L. Such polyurethane 202may be deposited with a nozzle or other means known to those of skill inthe art (see, e.g., FIG. 39). After the polyurethane hardens, in someembodiments the polyurethane may be buffed by a suitable brush or thelike to smoothly blend the surface of the grip while in otherembodiments, the polyurethane is not buffed.

Gripping surface GS includes outer surface 174 of layered sheet L,exposed surface E₁ and exposed surface E₂. In general, in embodimentslayered sheet L is wrapped around tube T such that layered sheet L abutsconnecting surface 46 of raised portion R at an intersection 178,wherein at least a portion of inner layer 50 and/or at least a portionof outer layer 52 abut connecting surface 46 of raised portion R.Desirably, inner layer 50 of layered sheet L is further adhered tosupport surface 12 of tube T1.

As shown, for example in FIGS. 40 through 42, inner layer 50 isdesirably adhered or bonded to support surface 12 and to connectingsurfaces 46 a and 46 b of raised portions R₁ and R₂. Outer layer 52 isalso desirably adhered or bonded to connecting surfaces 46 a and 46 b ofraised portions R₁ and R₂. Layered sheet L will be adhered to the raisedportion R by one or more suitable adhesives 180. A suitable adhesive hasa mixture of AD-86 (Toluene, 35%; Methyl Ethyl Ketone, 50%;Polyurethane, 15%) and AD-RFE (Ethyl Acetate, 78%; Polyisocynate, 22%).In some embodiments, and particularly in those wherein outer layer 52comprises a polyurethane, intersections 178 between layered sheet L andtube T may include, in addition to adhesive 180, a deposit ofpolyurethane 202 to assist in bonding or adhering layered sheet L, andin particular outer layer 52 of layered sheet L to raised portion R.Such polyurethane 202 may be deposited with a nozzle or other meansknown to those of skill in the art (see, e.g., FIG. 42). After thepolyurethane hardens, in some embodiments the polyurethane may be buffedby a suitable brush or the like to smoothly blend the surface of thegrip while in other embodiments, the polyurethane is not buffed. Theproximity of layered sheet L to raised portion R may not be uniform. Forexample, in some embodiments, portions of raised portion R may be withinapproximately ⅛ inch, 1/16 inch or in direct contact with the layeredsheet L around substantially the entire circumference of the raisedportion R.

In certain embodiments, thickness t_(R) of raised portion R is generallyconstant along its entirety and is configured to be approximately equalto thickness t_(L) of the layered sheet L (see, e.g., FIG. 40). In someembodiments, the approximately equal thicknesses of portion R andlayered sheet L promote a substantially smooth surface interface 176between the two as they cooperate to define gripping surface GS of gripG.

As mentioned above, it should be understood that the outer surface of agrip embodying the disclosure herein may be coated by means of a brushor spray or the like with a thin layer of polymer such as polyurethane(not shown) to, for example, protect such surface, add tackiness theretoand/or increase the durability thereof.

In some embodiments, tube T includes rubber with an IRHD hardness rating(International Rubber Hardness Degrees) between approximately 60 and 80degrees. In some embodiments, raised portion R also has an IRHD hardnessrating between approximately 60 and 80 degrees. As discussed above, insome embodiments outer layer 52 includes polyurethane. In someembodiments, outer layer 52 has an IRHD hardness rating of betweenapproximately 40 and 60 degrees. In some embodiments, the ratio of thehardness of outer layer 52 and raised portion R is approximately 1 to 1.In some embodiments, the hardness ratio is between approximately 1 to 2and approximately 1 to 1. In some embodiments where the hardness ratiois approximately 1 to 1, one or more other characteristics, such astackiness, durability, color, or friction enhancing pattern on the outersurface, may differentiate raised portion R and outer layer 52 on thegripping surface.

In one application, layered sheet L is adapted to provide a tacky, shockabsorbing surface while raised portions R are configured to provide moredurable surfaces. A user grasps the grip G with her left hand closest tocover 10. At least a portion of finger zone FZ of raised portion R₂engages at least a portion of the pads of a user's fingers closest tothe user's left palm. The upper portion of R₂ may extend a width w₂sufficient to provide a palm zone PZ on the front of grip G adapted toengage the meaty portion of the palm of the user's left hand. In someembodiments, that width w₂ extends 100% of the circumference of tube T.The user's left and right thumbs may then rest on the front of grip Gwhere raised portion R₁ is configured to engage the thumbs.

FIGS. 43 through 47 illustrate a modified tube T and layered sheet L. Asdiscussed above, in general connecting surface 46 desirably extendsbetween support surface 12 and exposed surface E of raised portion R andforms an angle α with a line tangent to the intersection of connectingsurface 46 of raised portion R and support surface 12 of tube T. Layeredsheet L is generally configured to engage connecting surface 46. Asshown in, for example FIG. 44, connecting surface 46 a extends betweensupport surface 12 and exposed surface E₁ of raised portion R₁ to forman angle α₁. In some embodiments, connecting surface 46 is transverse tosupport surface 12 such that angle α is approximately 90 degrees andedges 190 and 192 of layered sheet L are not skived so that they form acomplementary angle. In some embodiments, it may be advantageous toconfigure tube T such that angle α is greater than 90 degrees. In someembodiments, angle α is in the range of approximately 90 and 175degrees. In some embodiments, angle α is in the range of approximately95 and 150 degrees. In some embodiments, for example the embodimentshown in FIGS. 43 through 47, angle α is approximately 120 degrees. FIG.45 illustrates layered sheet L after being skived along its edges tocomplement the angle α of tube T illustrated in FIGS. 43 and 44. FIGS.46 and 47 show layered sheet L being wrapped about tube T and bonded totube T as described above.

Alternatively, it may be advantageous to configure tube T such thatangle α is less than 90 degrees (not shown). In some embodiments, angleα is in the range of approximately 5 and 90 degrees. In someembodiments, angle α is in the range of approximately 25 and 85 degrees.Forming connecting surface 46 of raised portion R to have an angle αless than 90 degrees allows the edges of layered sheet L to be hiddenbeneath at least a portion of connecting surface 46, particularly ifthickness t_(R) of raised portion R is greater than thickness t_(L), oflayered sheet L. In some embodiments, connecting surface 46 describes anangle α other than 90 degrees, and yet some or all of the edges oflayered sheet L are not skived to complement the angle α described byconnecting surface 46. In some such embodiments, particularly in thosewherein angle α is less than 90 degrees, gaps between layered sheet Land raised portion R may be left empty or filled with an adhesive orother bonding agent.

In some embodiments, connecting surface 46 describes a varied angle α.The edges of layered sheet L may have skiving to complement some or allof those angles.

In addition to being attached to tube T configured for use with irons,as shown in FIG. 2, any of the layered sheets disclosed herein may alsobe attached to a tube configured for use with putters (not shown). Sucha putter tube may include a substantially flat region as shown, forexample, in Applicant's U.S. Pat. Nos. 6,843,732 and 6,857,971. Inaddition, in such a putter grip, alternative arrangements of raisedportions R may be employed to accommodate various types of puttingstyles. For example, an additional finger zone FZ may be created on thefront of the grip and a thumb zone TZ may be created on the back of thegrip accommodate a player's “claw style” putting grip.

It will be understood that the foregoing is only illustrative of theprinciples of the inventions, and that various modifications,alterations and combinations can be made by those skilled in the artwithout departing from the scope and spirit of the inventions.

Referring to the drawings, FIGS. 48, 49 and 50 show a golf club C′having a shaft 20′ upon the handle H′ of which is installed a prior artresilient grip GPA′. Grip GPA′ includes a polyurethane-felt strip S′which is spirally wrapped about a resilient underlisting UPA′ similar tothat shown and described in my U.S. Pat. No. 6,386,989. A plurality ofsuch prior art golf club grips are inserted into and removed form aconventional golf bag B′ during play. As noted in FIG. 50, during suchinsertion and removal, the grips GPA′ of the golf clubs have slidingcontact with other golf club grips and the sides of the golf bag B′.Such contact causes the upper end of the resilient strips to unravelfrom the golf club handles. In FIGS. 48 and 49 there is shown the mannerin which unraveling of the upper end 19′ of resilient strip S′ takesplace. Such unraveling not only detracts from the appearance of thegrip, but is also distracting to a golfer when he takes a swing of theclub because of the rough feel of the unraveled portion of the strip.

Referring now to FIGS. 51-59, there are shown the components of apreferred form of golf club grip G′ embodying the present invention.Such grip includes resilient underlisting sleeve similar to thatdescribed in my U.S. Pat. No. 6,386,989. Sleeve U′ includes an integralcap 22′ at its upper end, while the lower end of the sleeve is formedwith an integral nipple 24′. The upper portion of nipple 24′ is formedwith a circumferential groove 25′ for a purpose described hereinafter.It should be particularly noted that the underside of cap 22′ is formedwith a circumferentially extending slot 26′ which receives the upper endof the resilient sleeve S′ of FIGS. 55-58 in a manner to be describedhereinafter.

More particularly, strip S′ is fabricated from first and secondindividual segments S1′ and S2′ of different widths, with segment S1′preferably being wider than segment S2′. Segment S1′ includes a bottombacking layer, 30′ (preferably of felt) having an inner or bottomsurface which is adhered to the aforedescribed underlisting sleeve U′.Segment S1′ also includes a top layer of a suitable resilient plasticmaterial, such as a smooth closed-pore polyurethane layer, generallydesignated 34′, with the polyurethane layer being bonded to the uppersurface of its adjacent bottom layer. The segment S1′ may be formed withvertical air-passing perforations (not shown) such as described in myU.S. Pat. No. 5,645,501 issued Jul. 8, 1997. Segment S2′ is similar inconstruction to segment S1′ and includes an open-pored bottom backinglayer, generally designated 36′ (preferably of felt), having an inner orbottom surface which is adhered to underlisting sleeve U′. Segment S2′also includes a top layer 40′ of a suitable resilient plastic materialsuch as polyurethane layer, with the polyurethane layer being bonded tothe upper surface of its adjacent backing layer 36′. The polyurethanelayer of each strip segment S1′ and S2′ may be formed in a conventionalmanner by coating a felt strip with one or more solutions ofpolyurethane (e.g., polyester or polyether) dissolved in a dimethylformamide (DMF), immersing the coated strip in water baths to displacethe DMF and cause the urethane to coagulate, and finally driving off thewater by the application of pressure and heat. In this manner, pores areformed in the polyurethane layer, while the underside of thepolyurethane layer is bonded to the upper surface of the felt layer. Thethickness of the polyurethane layer is preferably about 0.2-1.40millimeters and the thickness of the felt layer is about 0.7-1.90millimeters.

The felt layers 30′ and 36′ serve as backing layers for the polyurethanelayer 34′ and polyurethane coating 40′ so as to provide strength for thepolyurethane. The felt also cooperates with the polyurethane to assistin cushioning the shocks applied to a grip when a golf ball is struck bya golf club. It should be noted that other materials may be substitutedfor the felt as a backing layer to provide strength for the polyurethaneand to cushion shocks, e.g., a synthetic plastic such as anethylene-vinyl acetate copolymer, commonly known as EVA. The felt may befabricated of conventional suitable materials such as nylon, cotton,polyester or the like.

The entire underside of backing layer 30′ of segment S1′ is providedwith an adhesive 54′ initially covered in a conventional manner by apeel-away tape 56′. Peel-away tape 56′ includes a thin band 56B′ (notshown) which can be pulled off the main body of tape 56′ to exposeadhesive 54′ disposed on one edge of segment S1′, while the tapes' mainbody remains on the adhesive covering the remainder of the segment S1′.

Referring now to FIG. 58, the side edges of the polyurethane layer 34′of segment S1′ are formed with sidewardly and outwardly extendingreinforcement side edges 46′ and 47′. The side edges of the polyurethanelayer 40′ of segment S2′ are also formed with sidewardly and outwardlyextending reinforcement side edges 48′ and 49′. In FIG. 58, the sideedges of the felt layer 34′ of segment S1′ have been skived to formoutwardly and upwardly slanted side edges 50′ and 51′. Similarly, theside edges of felt layer of segment S2′ have been skived to formoutwardly and upwardly slanted side edges 52′ and 53′. The underside ofsegment S2′ is covered with an adhesive 58′ initially covered by apeel-away tape 59′ (FIG. 56). To combine segments S1′ and S2′ intocomposite strip S′, reinforced side edge 49′ of segment S2′ is thenplaced underneath skived side edge 50′ of segment S1′ as shown in FIG.58 and pressed onto segment S1′. The strip S′ is then cut on both endsto provide the leading edge and trailing edges 60′ and 62′.

It should be particularly noted that the upper area of polyurethanelayer 40′ of segment S2′ inwardly of the recessed side edges may beembossed with depressed indicia I′, such as the name of the manufacturerof the golf club grip. Such embossing serves not only as a decorativeenhancement of the golf club grip, but additionally, the embossingprocess densifies the polyurethane layer 40′ so as to reduce stretchingof the second segment and thereby increase the hoop strength of thestrip S′. It is also desirable to mold the polyurethane layer 34′ ofsegment S1′ in a first color while polyurethane layer 40′ of segment S2′is molded in a second color that contrasts with the first color. Withthis arrangement, a multicolored grip having a pleasing appearance willresult when the strip S′ is spirally wrapped about an underlistingsleeve.

Referring now to FIGS. 59-62, to secure the upper or leading edge 60′ ofresilient strip S′ within the circumferential slot 26′ of cap 22′, theupper edge of the strip is manually urged into the confines of the slot26′ (FIG. 60). After the upper edge of the strip S′ has been firmlypositioned within the slot 26′, the strip is spirally wrapped downwardlyalong the outer surface of the underlisting sleeve U′ (FIG. 61). Whenthe strip S′ has been spirally wound to a position wherein its lower ortrailing edge 62′ is disposed in horizontal alignment with the lowerportion of nipple groove 25′ the lower end portion of the strip ismanually urged into the confines of the groove by temporarily expandingthe peripheral lip 70′ formed outwardly of the groove so as to admit thelower edge of the strip into the groove. When the lip 70′ returns to itsoriginal position, the lip will securely retain the lower end of thestrip to the upper portion of the nipple as shown in FIGS. 63-65. Theresulting grip G′ embodying the present invention is shown in FIG. 66.Referring thereto, it will be seen that the upper end of strip S′ isrestrained against unraveling by being locked in cap slot 26′ while thelower end of such strip is restrained against unraveling by nipple lip70′. The aforedescribed arrangement for securing the upper edge of thestrip S′ is particularly useful in securely retaining a two-piece stripon the upper portion of the underlisting sleeve since the narrower stripsegment has a tendency to become unraveled.

The spiral wrapping of the strip S′ about the underlisting U′, and thepositioning of the upper and lower edges of the strip within the slot26′ and groove 25′ may take place when the underlisting sleeve ispositioned upon a mandrel M′ in a conventional manner. After the striphas been secured upon the underlisting U′, the sleeve and stripcombination may be removed from the mandrel and slipped onto the handleportion of a golf club shaft.

It should be understood that various modifications and changes may bemade with respect to the above-described embodiment without departingfrom the scope of the present invention. By way of example, theresilient strip may be of one-piece construction such as that shown inmy aforementioned U.S. Pat. No. 6,386,989, rather than the two segmentconstruction described hereinabove.

1. A grip for use with a golf club, said grip comprising: a tube havinga body with a first end, a second end including a cover defining asubstantially closed outer surface, a support surface positioned betweensaid first and second ends and a raised portion extending outwards fromsaid support surface and integrally formed with said support surface,said tube defining three regions of equal length extending from saidfirst end to said second end including a first region adjacent the firstend, a second region adjacent the second end, and a middle regionbetween the first and second ends; said first end comprising a lipextending toward said second end, said lip having an inner and an outersurface wherein said inner surface cooperates with a first portion ofsaid support surface to form a slot; said raised portion including anexposed surface and a connecting surface extending between said supportsurface and said exposed surface, a first section of said raised portionintegrally formed with said cover and having a length of at least aboutone half inch extending around the circumference of said tube such thatsaid raised portion forms a portion of a gripping surface configured tobe gripped by a user in the second region, and a second section of saidraised portion extending along said body toward said first end, saidsecond section extending to and ending in an elliptical-like point inthe first region, and said second section having a circumferential widthof no more than about 50% of the circumference of said tube body in themiddle region of said tube body; and a multilayered sheet comprising aninner layer and an outer layer, said multilayered sheet configured tooverlay said support surface and not said exposed surface of said raisedportion; said multilayered sheet being wrapped about said tube such thatsaid multilayered sheet contacts said support surface of said tube andwraps entirely around the circumference of said tube body near saidfirst end; and said inner layer of said multilayered sheet being adheredto said support surface, wherein said outer surface of said multilayeredsheet and said exposed surface of said raised portion cooperate todefine the a gripping surface.
 2. A grip as in claim 1, wherein aportion of said first section of said raised portion extends a minimumof at least approximately 2 inches toward said first end.
 3. A grip asin claim 1, wherein a portion of said multilayered sheet is configuredto be inserted into said slot.
 4. A grip as in claim 1, wherein saidfirst end further defines an opening configured to couple with the shaftof a golf club.
 5. A grip as in claim 1, wherein said exposed surface ofsaid raised portion includes a friction enhancing pattern.
 6. A grip asin claim 1, wherein said outer surface of said multilayered sheetincludes a friction enhancing pattern.
 7. A grip as in claim 1, whereinsaid first and second sections of said raised portion are separated byat least a portion of said support surface.
 8. A grip as in claim 7,wherein said second section is generally shaped in the form of anellipse having its long axis extending along the length of said body andhaving a second elliptical-like end located in said second region.
 9. Agrip as in claim 1, wherein at least one outer edge region of said sheetis skived.
 10. A grip as in claim 1, wherein said connecting surface istransverse to said support surface.
 11. A grip as in claim 1, whereinsaid connecting surface defines an angle with said support surface inthe range of approximately 90 degrees and 175 degrees.
 12. A grip as inclaim 1, wherein said connecting surface defines an angle with saidsupport surface in the range of approximately 95 degrees and 150degrees.
 13. A grip as in claim 1, wherein at least a portion of saidconnecting surface defines an angle with said support surface in therange of approximately 5 degrees and 90 degrees.
 14. A grip as in claim1, wherein at least a portion of said connecting surface defines anangle with said support surface in the range of approximately 25 degreesand 85 degrees.
 15. A grip as in claim 1, wherein said tube comprises amolded material.
 16. A grip as in claim 1, wherein said tube comprises amolded rubber.
 17. A grip as in claim 1, wherein said lip and said tubeare integrally formed.
 18. A grip as in claim 1, wherein said innerlayer of said sheet being adhered to said connecting surface is notskived.